Interference suppression module for an electrically commutated electric motor, method for manufacturing an interference suppression module and vehicle with such an interference suppression module

Abstract

Interference suppression module (5) for an electrically brushless commutated electric motor (2) comprising: - a circuit carrier (5.1), - an electronic circuit arrangement (5.2) arranged on the circuit carrier (5.1) and comprising at least one interference suppression component, - an encapsulation (5.3) that surrounds the electronic circuit arrangement (5.2) in a form-fitting and material-locking manner, and - at least one interface (5.4) which is provided for electrical contacting the electronic circuit arrangement (5.2) with a control unit (4) of the electrically brushless commutated electric motor (2), wherein the interface (5.4) is integrated into the circuit carrier (5.1), wherein the interference suppression module (5) is separate from the control unit (4), so that the at least one interference suppression component is arranged outside an electronics compartment of the control unit.

Description

[0001] The invention relates to an interference suppression module for an electrically commutated electric motor. The invention further relates to a method for manufacturing such an interference suppression module and to a vehicle equipped with such an interference suppression module.

[0002] Electrically commutated electric motors are well-known and are characterized by a reduced number of wear parts compared to brush-commutated electric motors. For example, such electric motors are used in vehicle transmissions, where they combine to form a geared motor.

[0003] Such an electric motor is controlled, for example, by pulse-width modulated power electronics integrated into a control unit, such as a transmission control unit. The power electronics circuit comprises three voltage dividers that split an input voltage, such as a 12V supply voltage from a vehicle's electrical system, into three phase voltages, each phase offset from the others by, for example, 120°. This means the electric motor is operated with three-phase alternating current.

[0004] Since the phase voltages can exhibit undesirable voltage spikes due to pulse width modulation, interference suppression is necessary to smooth the phase voltages. For example, ceramic capacitors or electrolytic capacitors are used as interference suppression components, but these have low temperature stability.

[0005] The invention is therefore based on the objective of providing an improved interference suppression module for an electrically commutated electric motor compared to the prior art. The invention further aims to provide a suitable method for manufacturing such an interference suppression module and a vehicle equipped with such an interference suppression module that is an improvement over the prior art.

[0006] Advantageous embodiments of the invention are the subject of the dependent claims.

[0007] With regard to the interference suppression module, the problem is solved according to the invention with the features specified in claim 1. With regard to the method, the problem is solved with the features specified in claim 9. With regard to the vehicle, the problem is solved according to the invention with the features specified in claim 10.

[0008] A suppression module for an electrically commutated electric motor comprises a circuit carrier, an electronic circuit arrangement arranged on the circuit carrier, an encapsulation that surrounds the electronic circuit arrangement in a form-fitting and material-locking manner, and at least one interface which is provided for electrical contacting the electronic circuit arrangement with a control unit of the electrically commutated electric motor.

[0009] A separate interference suppression module for the electric motor's control unit enables the circuit carrier to be populated with the electronic circuit arrangement, which includes interference suppression components, outside of the control unit's electronics compartment. Since interference suppression components, such as electrolytic capacitors, typically require a great deal of space and also exhibit low temperature stability, the separate interference suppression module according to the invention allows for space-optimized placement of the interference suppression components and an extended service life of the electronic circuit arrangement compared to the prior art.

[0010] Furthermore, the interference suppression module can be designed to be significantly flatter and modularly scalable compared to current technologies. Replacement of the interference suppression module is also easily possible in the event of repair. In addition, the interference suppression module can be manufactured separately from the control unit, and no separate housing is required on the control unit to protect the interference suppression components, as the electronic circuitry is protected from external influences, such as gear oil, by the encapsulation.

[0011] For example, the interference suppression module can be coupled with a transmission control unit, which controls a vehicle's transmission motor. In this case, the control unit is the transmission control unit, and the electric motor, together with the vehicle's transmission, forms the transmission motor.

[0012] According to one embodiment of the invention, the interface for electrical contacting of the interference suppression module is designed as a stamped grid that is integrated into the circuit carrier.

[0013] In alternative configurations, the interface comprises an exposed contact surface that is electrically connected to the electronic circuit arrangement via an electrical conductor integrated into the circuit carrier. Advantageously, one side of the interference suppression module facing away from the control unit has no open electrical contacts, thus preventing short circuits.

[0014] Furthermore, according to one embodiment of the invention, the interface can be designed as a plug module comprising at least one electrical contact pin and a further encapsulation that surrounds the contact pin in a form-fitting and material-locking manner. The interference suppression module can thus be easily connected to the control unit.

[0015] Preferably, the encapsulation and the further encapsulation are formed as a single unit. This makes manufacturing the interference suppression module with a plug-in module particularly easy, as the need for a separate housing is eliminated.

[0016] The electronic circuit arrangement is preferably connected to the circuit carrier by a material bond. For example, the electronic circuit arrangement is bonded to the circuit carrier, e.g., using a thermally conductive adhesive. Alternatively, the electronic circuit arrangement can also be soldered or welded to the circuit carrier. Bond wires can also be provided for electrical contact between the electronic circuit arrangement and the circuit carrier. Furthermore, mechanical fixing is possible, e.g., via a screw point, a socket, or by means of a retaining device, e.g., a retaining clip.

[0017] The electronic circuit arrangement includes at least one capacitor, e.g. a ceramic capacitor or an electrolytic capacitor, as interference suppression components.

[0018] Furthermore, a method for manufacturing an interference suppression module for an electrically commutated electric motor is to be specified, wherein an electronic circuit arrangement is arranged and fixed on at least one flat side of a circuit carrier, wherein at least one interface for electrical contacting the electronic circuit arrangement with a control unit of the electrically commutated electric motor is integrated into the circuit carrier, and wherein at least the electronic circuit arrangement is provided with a curable encapsulation material which, upon curing, bonds to the electronic circuit arrangement in a form-fitting and material-locking manner and encapsulates it in one piece.

[0019] The process enables the simple and cost-effective production of an interference suppression module, which can be easily coupled to a control unit for controlling the electric motor.

[0020] Furthermore, a vehicle is provided which comprises an electrically commutated electric motor, a control unit for controlling the electric motor and an interference suppression module according to the invention, which is at least electrically connected to the control unit.

[0021] By extending the lifespan of the electronic circuitry using the interference suppression module, the functionality of the electric motor, and thus, for example, the vehicle's geared motor, can be maintained in the long term. The vehicle is therefore improved in terms of lifespan and functionality compared to the state of the art.

[0022] Exemplary embodiments of the invention are explained in more detail below with reference to drawings.

[0023] This shows:

[0024] Fig. 1 schematically a vehicle with an electric motor, a control unit for controlling the electric motor and an interference suppression module according to the invention,

[0025] Fig. 2 schematically the interference suppression module in a general design, and

[0026] Fig. 3 to Fig. 6 schematic sectional views of the interference suppression module in various exemplary configurations.

[0027] Corresponding parts are marked with the same reference symbols in all figures.

[0028] Fig. Figure 1 schematically shows a vehicle 1 in a highly simplified manner.

[0029] The vehicle 1 includes an electrically commutated electric motor 2 , which in the present embodiment is equipped with a gearbox 3 of the vehicle 1 a GM geared motor and a control unit 4 is being targeted.

[0030] For example, the gearbox 3 an automatic vehicle transmission whose driving stages are controlled by the electric motor 2 be adjusted.

[0031] The electric motor 2 It is electrically commutated and therefore designed as a brushless motor. The control of the electric motor 2 This is done via the control unit 4 , which for example features pulse-width modulated power electronics (not shown here).

[0032] As already described at the beginning, the power electronics comprise three voltage dividers that supply an input voltage, e.g. a 12V supply voltage from the vehicle's electrical system. 1 , divided into three phase voltages, each of which is, for example, 120° out of phase with each other. That is, the electric motor 2 It is operated with three-phase alternating current.

[0033] Since the phase voltages can exhibit undesirable voltage spikes due to pulse width modulation, a suppression module according to the invention is required. 5provided, which is necessary for smoothing the phase voltages.

[0034] The interference suppression module 5 is connected to the control unit 4 electrically and, if necessary, additionally mechanically connected, and is manufactured and assembled as a separate module.

[0035] Fig. 2 shows the interference suppression module 5 in a general version in a highly simplified manner.

[0036] The interference suppression module 5 includes a circuit carrier 5.1 e.g. a so-called HDI printed circuit board, on which an electronic circuit arrangement is mounted. 5.2 arranged and bonded together, e.g. by gluing, welding or soldering.

[0037] The electronic circuit arrangement 5.2The interference suppression components comprise a specified number of capacitors, in particular electrolytic capacitors and / or ceramic capacitors. Electrical contact between the interference suppression components and the circuit carrier is required. 5.1 This is done, for example, by wire bonding, soldering, welding and / or by using a thermally conductive adhesive.

[0038] The encapsulation 5.3 surrounds all components on the circuit board 5.1 , in particular the electronic circuit arrangement 5.2 , completely and in one piece, so that they are protected from external influences such as chips, gear oil.

[0039] Due to the one-piece design of the encapsulation 5.3 are also the spaces in the electronic circuit arrangement 5.2 sealed, so that open interfaces are avoided. By means of encapsulation 5.3This enables an optimal combination of electronic protection and a housing concept with a reduced installation space requirement compared to the state of the art. Furthermore, due to the encapsulation 5.3 No separate housing required.

[0040] The encapsulation is preferably 5.3 formed from a curable material, e.g. a thermoset, so that the form and material bond between the encapsulation and the electronic circuit arrangement 5.2 It is particularly easy to manufacture. The curable material can be applied using compression molding, injection molding, or alternatively, injection casting.

[0041] Furthermore, the interference suppression module includes 5 at least one interface 5.4 , which are used for the electrical contacting of the electronic circuit arrangement 5.2 with the power electronics of the control unit 4 is planned.

[0042] The interface5.4 can be trained in various ways, which will be discussed in the following. Fig. 3 to Fig. Section 6 will be discussed in more detail.

[0043] The Fig. 3 to Fig. Figure 6 shows various exemplary designs of the interference suppression module. 5 , where the interference suppression module 5 Each is shown in a sectional view, in particular in a longitudinal section.

[0044] In Fig. 3 is the interface 5.4 designed as a stamped grid S, wherein two parallel electrical conductors run through the circuit carrier 5.1 are guided through and from a populated flat side of the circuit carrier 5.1 protrude upwards. The stamped grid S is electrically conductive with the electronic circuit arrangement. 5.2 connected, e.g. via the circuit carrier 5.1 progressive die-cut grid sections.

[0045] The populated flat side of the circuit board 5.1 This includes, for example, one of the control units. 4 Facing side. An unpopulated flat side of the circuit board. 5.1 is the control unit 4 turned away, over the unpopulated flat side of the circuit carrier 5.1 Protruding sections of the conductors are sealed with an electrically insulating material. Alternatively, the circuit carrier can be 5.1 also differently relative to the control unit 4 be aligned.

[0046] Alternatively, a similar interface can be used. 5.4 a cable or a press-fit contact is arranged or inserted, wherein these are connected to the electronic circuit arrangement 5.2 each, for example, via one in the circuit carrier 5.1 The integrated conductor track is electrically connected.

[0047] In Fig. 4 includes the interface 5.4an exposed contact surface K on the populated flat side or alternatively on an opposite flat side of the circuit carrier 5.1 , which are connected to the circuit carrier 5.1 The integrated conductor element L is connected. The conductor element L can also be a conductive trace and is electrically connected to the electronic circuit arrangement. 5.2 tied together.

[0048] The electrical contact surface K is either designed in the form of a surface-mounted component and mounted directly onto the circuit carrier. 5.1 soldered or as an open conductor area of ​​the circuit carrier 5.1 The contact surface K is advantageously formed from an electrically conductive material, e.g., metal or an electrically conductive ceramic. The contact surface K is preferably formed from an electrically conductive material, e.g., metal or ceramic.

[0049] Preferably, the unpopulated flat side of the circuit carrier has5.1 no open electrical contact points.

[0050] In the Fig. 5 and Fig. 6 is the interface 5.4 each designed as an integrated connector module SM, which has two parallel contact pins KS, each located above or, depending on the installation space, also below the populated flat side of the circuit carrier. 5.1 are angled at right angles.

[0051] In Fig. 5. The contact pins KS are surrounded by a further encapsulation KP, which is separate from the encapsulation. 5.3 the electronic circuit arrangement 5.2 is trained.

[0052] In Fig. 6 are the encapsulation 5.3 and the further encapsulation KP are formed in one piece together, so that they are used in the manufacture of the interference suppression module. 5 can be applied in a single procedural step.

[0053] Using the SM connector module as an interface 5.4 can the interference suppression module 5 in a particularly simple way with the control unit 4 be connected. The control unit 4 It features a connector socket corresponding to the SM connector module.

[0054] The electrical contact pins KS can be positioned from both sides, e.g., by inserting them and then soldering, welding, or gluing them on both sides. Alternatively, the electrical contact pins KS can also be soldered, welded, or glued on one side only. Reference symbol list 1 vehicle 2 electric motors 3 gearboxes 4 Control unit 5 Interference suppression module 5.1 Circuit carrier 5.2 Electronic circuit arrangement 5.3 Encapsulation 5.4 Interface GM geared motor K Contact surface KS contact pin KP further encapsulation L conductor element S punch grid SM connector module

Claims

[1] Interference suppression module ( 5 ) for an electrically commutated electric motor ( 2 ) with – a circuit carrier ( 5.1 ), – an electronic circuit arrangement ( 5.2 ), which are located on the circuit board ( 5.1 ) is arranged, – an encapsulation ( 5.3 ), which the electronic circuit arrangement ( 5.2 ) surrounds in a form-fitting and material-locking manner, and – at least one interface ( 5.4 ), which are used for the electrical contacting of the electronic circuit arrangement ( 5.2 ) with a control unit ( 4 ) of the electrically commutated electric motor ( 2 ) is planned. [2] Interference suppression module ( 5 ) according to claim 1, wherein the interface ( 5.4 ) is designed as a punched grid (S). [3] Interference suppression module ( 5 ) according to claim 1 or 2, characterized by that the interface ( 5.4) comprises an exposed contact surface (K) which extends into the circuit carrier ( 5.1 ) integrated electrical conduction element (L) electrically connected to the electronic circuit arrangement ( 5.2 ) is connected. [4] Interference suppression module ( 5 ) according to one of the preceding claims, wherein the interface ( 5.4 ) is designed as a plug module (SM) which has at least one electrical contact pin (KS) and a further encapsulation (KP) which surrounds the at least one electrical contact pin (KS) in a form-fitting and material-locking manner. [5] Interference suppression module ( 5 ) according to claim 4, wherein the encapsulation ( 5.3 ) and the further encapsulation (KP) are formed as a single unit. [6] Interference suppression module ( 5 ) according to one of the preceding claims, wherein the electronic circuit arrangement ( 5.2 ) with the circuit carrier ( 5.1 ) is bonded by a material connection. [7] Interference suppression module (5 ) according to one of the preceding claims, wherein the electronic circuit arrangement ( 5.2 ) has at least one capacitor. [8] Interference suppression module ( 5 ) according to claim 7, wherein the at least one capacitor is designed as an electrolytic capacitor. [9] Method for manufacturing an interference suppression module ( 5 ) for an electrically commutated electric motor ( 2 ), where – on at least one flat side of a circuit board ( 5.1 ) an electronic circuit arrangement ( 5.2 ) is arranged and fastened – at least one interface ( 5.4 ) for electrical contacting of the electronic circuit arrangement ( 5.2 ) with a control unit ( 4 ) of the electric motor ( 2 ) into the circuit carrier ( 5.1 ) is integrated, and – at least the electronic circuit arrangement ( 5.2) is provided with a curable encapsulation material which, upon curing, bonds with the electronic circuit arrangement ( 5.2 ) connects in a form-fitting and material-locking manner and encapsulates it in one piece. [10] vehicle ( 1 ), comprehensive – an electrically commutated electric motor ( 2 ), – a control unit ( 4 ) to control the electric motor ( 2 ) and – a interference suppression module ( 5 ) according to one of claims 1 to 8, which is connected to the control unit ( 4 ) is at least electrically connected.

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